Deformation-based additive manufacturing optimization

ABSTRACT

A system and method that relies on the principles of material science, deformable body mechanics, continuum mechanics and additive manufacturing to reduce the costs associated with additive manufacturing. Physical properties are used by numerical solution methods, such as the Finite Element Method (FEM) or Smooth Particle Hydrodynamics (SPH), to deform an original model of an object to be manufactured into a viable configuration that reduces fabrication material, time, and cost when manufacturing an object through additive manufacturing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This nonprovisional application claims priority to provisionalapplication No. 62/721,086, entitled “DEFORMATION-BASED ADDITIVEMANUFACTURING OPTIMIZATION,” filed Aug. 22, 2018 by the same inventors.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates, generally, to additive manufacturing. Morespecifically, it relates to the optimization of additive manufacturingthrough the simulated deformation of the object to be manufactured.

2. Brief Description of the Prior Art

Additive manufacturing relies on support material for the fabrication ofcomplex parts or assemblies featuring overhangs, enclosed volumes, orsimilar structures that would otherwise fail during manufacturing. Theuse of support material directly increases costs because more time andmaterial are expended while building the support material. Costs alsorise proportional to the time needed for the removal of the supportmaterial from the finished part. Even in the best-case scenario in whichthe support material simply dissolves in solution, costs are affected bythe price of the solvents, time of dissolution, and drying time.

Accordingly, what is needed is a method of additive manufacturing toreduce or eliminate support material when manufacturing complex parts orassemblies that would typically require support material. However, inview of the art considered as a whole at the time the present inventionwas made, it was not obvious to those of ordinary skill in the field ofthis invention how the shortcomings of the prior art could be overcome.

All referenced publications are incorporated herein by reference intheir entirety. Furthermore, where a definition or use of a term in areference, which is incorporated by reference herein, is inconsistent orcontrary to the definition of that term provided herein, the definitionof that term provided herein applies and the definition of that term inthe reference does not apply.

While certain aspects of conventional technologies have been discussedto facilitate disclosure of the invention, Applicants in no way disclaimthese technical aspects, and it is contemplated that the claimedinvention may encompass one or more of the conventional technicalaspects discussed herein.

The present invention may address one or more of the problems anddeficiencies of the prior art discussed above. However, it iscontemplated that the invention may prove useful in addressing otherproblems and deficiencies in a number of technical areas. Therefore, theclaimed invention should not necessarily be construed as limited toaddressing any of the particular problems or deficiencies discussedherein.

In this specification, where a document, act or item of knowledge isreferred to or discussed, this reference or discussion is not anadmission that the document, act or item of knowledge or any combinationthereof was at the priority date, publicly available, known to thepublic, part of common general knowledge, or otherwise constitutes priorart under the applicable statutory provisions; or is known to berelevant to an attempt to solve any problem with which thisspecification is concerned.

BRIEF SUMMARY OF THE INVENTION

The long-standing but heretofore unfulfilled need for a method ofadditive manufacturing to reduce or eliminate support material whenmanufacturing complex parts or assemblies that would typically requiresupport material is now met by a new, useful, and nonobvious invention.

The novel method for the reducing the time and costs associated withmanufacturing an object through additive manufacturing, includesacquiring a digital model of the object to be manufactured, wherein thedigital model has a first shape; discretizing the digital model;digitally altering the first shape of the discretized digital model toproduce an altered digital model that requires less support material foradditive manufacturing than would be necessary for additivemanufacturing of the discretized digital model; sending the altereddigital model to an additive manufacturing device; manufacturing theobject in accordance with the altered digital model using the additivemanufacturing device; and removing any support material from the objectmanufactured by the additive manufacturing device.

In an embodiment, the step of altering the shape of the discretizeddigital model includes elastically deforming the shape of thediscretized digital model. In an embodiment, the step of altering theshape of the discretized digital model further includes applying asimulated force evenly about a body of the discretized digital model. Anembodiment may also include reducing a cross-sectional area of thediscretized digital model to reduce the amount of required supportmaterial to manufacture the object.

In an embodiment, the digital object to be manufactured includes one ormore joints and the step of altering the shape of the discretizeddigital model further includes manipulating the shape of the discretizeddigital model about the one or more joints.

An embodiment further includes a step of validating that the objectmanufactured can be shaped into the unaltered shape of the digital modelwithout plastically deforming. The step of validating may includeidentifying a manufacturing material; identifying limits for elasticdeformation of the manufacturing material; and determining whether thestep of altering the shape of the discretized digital model to producethe altered digital model includes a deformation beyond the limits forelastic deformation of the manufacturing material. Responsive to adetermination that the altered digital model includes a deformationbeyond the limits for elastic deformation of the manufacturing material,an embodiment alters the shape of the discretized digital model suchthat the deformation is within the limits for elastic deformation of themanufacturing material.

An embodiment further includes a step of optimizing the shape of thealtered digital model to minimize the amount of required supportmaterial to manufacture the object. An embodiment may also include anestimation step during which the digital model of the object to bemanufactured is divided into at least two segments, whereby each segmentcan be discretized and altered in shape to allow for segment-specificalteration-based optimization.

An embodiment of the novel method for the reducing the time and costsassociated with manufacturing an object through additive manufacturingincludes dividing the digital model of the object into at least twosegments. The discretizing step also includes discretizing the segmentsto produce discretized segments of the digital model. Then the shape ofat least one of the discretized segments can be altered to produce analtered digital model that requires less support material for additivemanufacturing than would be necessary for additive manufacturing of thedigital model. This embodiment further includes the steps of sending thealtered digital model to an additive manufacturing device; manufacturingthe object in accordance with the altered digital model using theadditive manufacturing device; and removing any support material fromthe object manufactured by the additive manufacturing device.

The step of altering the shape of at least one of the discretizedsegments includes elastically deforming the shape of the at least one ofthe discretized segment in an embodiment. In an embodiment, the step ofaltering the shape of at least one of the discretized segments furtherincludes applying a simulated force on at least one of the discretizedsegments. In an embodiment, the step of altering the shape of at leastone of the discretized segments further includes reducing across-sectional area of the at least one discretized segment to reducethe amount of required support material to manufacture the object.

In an embodiment in which the digital model is divided into segments,the digital model to be manufactured includes one or more joints and thestep of altering at least one of the discretized segments furtherincludes manipulating the shape of the at least one discretized segmentabout the one or more joints.

An embodiment also includes a step of validating that the objectmanufactured can be shaped into the unaltered shape of the digital modelwithout plastically deforming. The step of validating includesidentifying a manufacturing material; identifying limits for elasticdeformation of the manufacturing material; and determining whether thestep of altering the shape of the discretized digital model to producethe altered digital model includes a deformation beyond the limits forelastic deformation of the manufacturing material. Responsive to adetermination that the altered digital model includes a deformationbeyond the limits for elastic deformation of the manufacturing material,the system alters the shape of at least one of the discretized segmentssuch that the deformation is within the limits for elastic deformationof the manufacturing material.

An embodiment further includes a step of optimizing the shape of thealtered digital model to minimize the amount of required supportmaterial to manufacture the object.

These and other important objects, advantages, and features of theinvention will become clear as this disclosure proceeds.

The invention accordingly comprises the features of construction,combination of elements, and arrangement of parts that will beexemplified in the disclosure set forth hereinafter and the scope of theinvention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the invention, reference should be made tothe following detailed description, taken in connection with theaccompanying drawings, in which:

FIG. 1A is a graphic representation of a virtual model of an object tomanufactured using a standard method of additive manufacturing, shown onthe left, can be deformed, as shown on the right, to reduce the amountof required support material to build the, which is provided in themiddle.

FIG. 1B is a graphic representation of the virtual model in FIG. 1A withthe necessary support material added to the object during a standardmethod of additive manufacturing.

FIG. 1C is a graphic representation of the virtual model in a deformedstate with the necessary support material added to the object duringadditive manufacturing in accordance with the present invention.

FIG. 2 is a flowchart of an embodiment of the present invention.

FIG. 3 is a flowchart of an embodiment of the present invention.

FIG. 4 is a flowchart of an embodiment of the present invention.

FIG. 5 is a flowchart of an embodiment of the present invention.

FIG. 6A is digital representation of an object being segmented.

FIG. 6B is a digital representation of a single segment being deformed.

FIG. 6C depicts the same digital representation as shown in FIG. 6B, butwith a greater deformation force having been applied to the same segmentbeing deformed in FIG. 6B.

FIG. 6D depicts the same digital representation as shown in FIG. 6C, butwith a greater deformation force having been applied to the same segmentbeing deformed in FIG. 6C.

FIG. 7 is a chart depicting deformation of a model through theapplication of a uniform force, such as gravity.

FIG. 8 is a perspective view of two digital models of an elastic sleeveshown in an undeformed configuration on the left and a deformedconfiguration on the right.

FIG. 9 is a perspective view of two digital models of an elastic braceshown in an undeformed configuration on the left and a deformedconfiguration on the right.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description of the preferred embodiments,reference is made to the accompanying drawings, which form a partthereof, and within which are shown by way of illustration specificembodiments by which the invention may be practiced. It is to beunderstood that other embodiments may be utilized and structural changesmay be made without departing from the scope of the invention.

As used in this specification and the appended claims, the singularforms “a,” “an,” and “the” include plural referents unless the contentclearly dictates otherwise. As used in this specification and theappended claims, the term “or” is generally employed in its senseincluding “and/or” unless the context clearly dictates otherwise.

Referring to FIG. 1, exemplary hollow object 10 shown in FIG. 1Arepresents an object to be manufactured. Standard additive manufacturingrequires support material 12, both in and around desired object 10, asdepicted in FIG. 1B. The depicted support material 12 increases materialcosts, printing time, and final preparation time because supportmaterial 12 must be removed post production. The present inventionincludes a system and method that dramatically reduces the use ofsupport material 12, build time, and costs, by deforming the digitaldesign of the original object 10 as shown in FIG. 1C. The deformation ofthe object reduces spaces that require support material, which resultsin far less support material 12.

The present invention, when presented with an input model of anoriginal/undeformed object or the original/undeformed object itself,will create a digital model or use the input model of theoriginal/undeformed object itself and then strategically deform thedigital model of the object into viable printable configurations. In anembodiment, the present invention uses physical simulation methods, suchas finite element analysis (FEA) and smooth particle hydrodynamics(SPH), to generate a viable deformed configuration of the digital designfor the original object or combination of object segments.

Referring now to FIG. 2, an embodiment of the present invention beginswith retrieving and/or creating an undeformed, preferably 3-dimensional,digital model of the object to be manufactured at step 14. In anembodiment, the undeformed digital model of the object is divided into aplurality of segments or may be treated as a single segment. Objectsegmentation is further discussed below.

At step 16, the model is discretized using standard discretizationmethods known to a person of ordinary skill in the art. Thediscretization step 16 discretizes or divides the undeformed digitalmodel of the object, or at least one undeformed segment of the digitalmodel into finite single or multi-dimensional elements. Characteristicsof these elements depend on the simulation method to be used on theobject. For example, FEA requires discretization in 2D or 3D elements,while SPH requires discretization in particles.

The discretized digital model, or at least one segment of thediscretized digital model, is then deformed/altered in shape at step 18using, e.g. standard meshing tools and physical simulation methods, suchas FEA or SPH. In an embodiment in which the digital model has beendivided into a plurality of segments, deformation may be limited to asubset of the plurality of discretized, undeformed segments. Moreover,the deformation of each discretized, undeformed segment can beindependent and may differ from other discretized, undeformed segments.

The deformation of the discretized, undeformed digital model of theobject or segments may be strain- or force-induced, including but notlimited to compressing, collapsing, stretching, twisting, bending, andtorqueing the digital model of the object or segments of the objects.Moreover, the deformation may be achieved in several ways, including butnot limited to; applying a force or strain to a single or multiplenodes, facets, elements or locations on the body of the discretizedmodel, simulating an internal and/or external pressure force from withinand/or around the discretized model, and applying non-uniform forces atdifferent locations along the body of the discretized model. Forexample, the system or user compresses or collapses the digital model ofthe object using a body force, e.g. gravity (Weight=mass*gravity). Theforce may be applied to a center of mass and the program simulates howthe digital model would come to a resting position and deform.

Deformation may also include the manipulation of an adjustable objectabout the object's points of adjustment. For example, the object mayinclude hinges or other mechanical structures that allow the object toalter in shape or size as needed for the object to perform its intendedfunction. For such an object, the deformation step 18 may be anondeforming adjustment of the object about its points of adjustmentrather than an elastic deformation of the object. Elastic deformation,however, may be combined with a nondeforming adjustment of the objectabout its points of adjustment during the deformation step.

The embodiment depicted in FIG. 2, further includes validation step 20.Validation refers to the invention's capacity to corroborate theviability of the deformation based on an understanding of the physicalproperties/characteristics of the material(s), structure, and shape ofthe object. The physical properties of the materials are used todetermine elastic and plastic deformation limits. The validation stepensures that the simulation is possible, and the material used duringprinting can recover from the deformation. This can be accomplished byreferencing material properties or simulating the opposite deformation.

Knowing the elastic and plastic deformation limits, the amount ofstress/strain to be applied to the model is determined to avoid plasticdeformation. The system or a user sets a maximum stress/strain limit andthe system applies corresponding forces to avoid exceeding the maximumstress/strain limit. The level of deformation must not exceed arecoverable deformed configuration, i.e. the level of deformation mustnot exceed elastic deformation for an elastic object. By manufacturingthe object within the elastic or recoverable region of the material'sphysical characteristics, the object can be manufactured in a deformedstate and then the final manufactured object can be manipulated/deformedto the desired usable configuration with low risk of the object failingfrom stress, i.e. plastically deforming and/or breaking.

The validation step may also consider the degree of movement of sectionsof the object about its hinges or other mechanical structures. Forexample, a certain hinge may only allow for 120 degrees of rotation. Thevalidation step ensures that the degree of proposed movement about theobjects mechanical structures does not extend beyond the physicalcapabilities of the mechanical object. The physical capabilities of themechanical object may be predefined or entered by a user.

Once the deformed or altered configuration is validated, the systemmanufactures the object using additive manufacturing at step 24. In anembodiment, the deformed configuration is first presented to the user atstep 22. In an embodiment, the deformed model is presented to a user atstep 22 and waits for user instruction on whether to move on tomanufacturing step 24.

Referring now to FIG. 3, an embodiment includes optimization step 21.Optimization step 21 enhances the deformation of the discretized,undeformed model of the object, or at least one discretized, undeformedsegment, with the purpose of minimizing support material, print time,and associated costs. Given at least one viable deformed segment, theoptimization process may force reiterations of the deformation andvalidation processes to reduce support material, print time, andassociated costs. Reiteration includes the alteration of deformationparameters such as, but not limited to; deformation type (force, strain,pull, compression, torque, etc.), deformation scheme (orientation,boundary conditions, etc.), deformation magnitude (increase or decreaseforce, strain, etc.), and material and material properties. Boundaryconditions refer to the identification of certain portions of thedigital object that are intended to have different properties inrelation to other portions of the object. The consideration is similarto how a segmented object can be deformed differently for differentsegments. For example, an object to be printed may include a rigidportion and a flexible portion. The system and method allows a user tocreate a digital boundary, such as boundary line 44 in FIG. 6, foreither portion and set material properties and other characteristics forthe bounded portion of the object.

Optimization step 21 may also include automated suggestions regardingthe use of different printing materials available to the printer inorder to improve outcomes. Printing materials may vary in mechanicalproperties (e.g. elasticity, rigidity, compliance), thus yieldingdifferent deformed configurations, build times, and material usage.Suggestions are based on the materials available to the printer ormaterials that can be made by the printer. Suggestions may leverageadditional methods for the design and manufacture of composites, whichmay yield custom mechanical responses.

An embodiment of the optimization step 21 also includes optimization foreach identified segment of the digital object when the object has beendivided into segments. Suggestions would also be provided by segment.

The result of the optimization routine 21 may entail single or multiplesolutions. When multiple solutions are returned, there may be someconfigurations that only minimize material, time, or associated costsrather than minimizing all three. Likewise, some solutions may optimizetwo of the three optimization factors. Preferably each embodiment havingan optimization routine includes a validation step occurring at the endof every optimization loop to ensure that alternative deformationparameters and/or deformation scheme are plausible and within themechanical properties of the materials.

In an embodiment, optimization step 21 is performed a set number oftimes and the iteration that reduces the most support material, printtime, and associated costs is selected to be manufactured.Alternatively, an embodiment may include a minimum threshold for thereduction in support material, print time, and/or associated costs,which is used as an indicator as to whether the deformed model is movedto manufacturing step 24. The system may also, or alternatively, presentthe optimized deformation to a user at step 22 during which the user caninstruct the system to continue optimization or send the deformed modelto manufacturing step 24.

Referring now to FIG. 4, the system includes an initial estimation step15 following retrieval of the undeformed configuration at step 14.Estimation step 15 includes determining, calculating and/or estimating abaseline print path, support material requirement, and support materialdistribution. These parameters are usually obtained through a standardprocess called “slicing.” Three dimensional printer manufacturersusually distribute their own slicer, while a few community-drivenexamples do exist. While slicers typically rely on surface cuts,estimation step 15 improves upon the standard slicing process byapplying a voxelizer. The voxelizer divides/segments the object intovoxels (i.e. 3D pixels/volumetric points). By identifying the print pathand the necessary amount of support material to manufacture theundeformed object, estimation step 15 enables the object to be segmentedbased on the distribution of the support material. This is donespecifically to allow for segment-specific deformation-basedoptimization. In addition to print path and overall support materialrequirements, estimation step 15 results in at least one segment of theoriginal object model, based on the support material distribution. Whenthere is only one segment, that segment entails the entire object model.

Consider for example a model of a skull having various compartments thatrequire different amounts of support material or a flexible telescopingtube that has rigid, non-flexible regions that should not be deformedduring the manufacturing process. Each object to be manufactured mayhave regions/segments that deform more or less than others. Estimationstep 15 helps identify these segments that require different amounts ofsupport and deformation.

To accomplish the variability of deformation, estimation step 15automatically segments the object using the voxelizer. The voxelizerestimates the amount of support material required to manufacture theentire object. Segments are determined by the distribution of thesupport. Automation may be dependent on user inputted requirements. Forexample, if the only requirement is to reduce support by a setpercentage or value, then the degree of deformation can be scaled up toincrease the deformation as needed for each segment. In this case,segments requiring more support will undergo a more significantdeformation. Another example includes requiring a specific type ofsupport structure to be suppressed. Types of support include, but arenot limited to, (1) from part, (2) from build platform. Overhangsdirectly above the build platform require support that originates fromthe build platform. The link between cylindrical channels in FIGS. 6A-6Drequires support from the build platform. A requirement may specificallytarget the suppression of this type of support, as it is the mostwasteful. The requirement would then force a more significantdeformation on segments supported from the build platform. Estimationstep 15 may also consider the rigidity/flexibility and the structuralproperties of the object to be manufactured, which can be input by auser on a segment by segment basis.

FIG. 5 provides a flowchart depicting how the present invention handlesa segmented object. The system first acquires or is presented with adigital model of the unaltered/undeformed configuration of the object tobe manufactured at step 14. At estimation step 15, the systemdetermines, calculates or estimates the baseline print path, supportmaterial requirement, and support material distribution.

The estimation step further segments the original unaltered/undeformedobject either automatically or via user interaction. The segmentationcompensates for regions of the object that have different materialproperties and/or different intended uses. For example, the exemplaryobject in FIGS. 6A-6D is segmented/divided into two regions 40, 42 by auser-added segmentation line 44. In this example, region 40 isidentified as a segment to be deformed during manufacturing, whileregion 42 is will not be deformed during manufacturing. While theexample provided above relies on a segmentation line 44, an embodimentmay rely on any type of digital communication to segment a digital modelof an object, including, but not limited to, slicing, encircling,highlighting, and using a coordinate system.

Following the segmentation in the estimation step 15, an embodiment ofthe system outputs the undeformed segmented model of the object to theuser at step 26. The user has the option to modify the segments asdeemed necessary. Once the user has accepted the segmentation orfinalized the segmentation of the undeformed model, the systemdiscretizes the segmented model at step 16. In an embodiment, thediscretized segments are presented to the user in step 28. Again, theuser may be presented with the option to modify the discretized segmentsas shown in step 28.

The system continues to deformation step 18 during which the discretizedsegments are deformed as described previously herein. If certainsegments are identified by the user or system as segments not to bedeformed, then those segments are not deformed. In an embodiment, thesystem provides a user with the information regarding which segments areto be deformed, how they will be deformed, and to what degree they willbe deformed in step 30. The user has the option to adjust thedeformation plan for each segment.

Once the deformation plan has been finalized and/or approved by theuser, the deformation plan is validated in step 20. Validation step 20ensures that the imposed deformation falls within the recoverable orelastic range of the material(s) that constitute the original object. Ifat least one of the deformed segments does not represent a viabledeformed segment, the system, at step 38, reverts back to deformationstep 18 to reiterate the deformation process 18. Deformation step 18then alters parameters such as, but not limited to, the magnitude of thedeformation. In an embodiment, the validation information is presentedto the user at step 32 and the user can modify the validationinformation for each segment.

Following validation of the deformation of each segment, the systemoptimizes the deformation of each segment at step 21 to minimize supportmaterial, print time, and associated costs. If the system determinesthat the deformation can be further optimizes, the at step 36, thesystem instructs the reiteration of deformation step 18 to modify thedeformation scheme, type of deformation, magnitude of deformation,and/or material properties. In an embodiment, the optimizationinformation is presented to the user at step 34 and the user canoverride or approve the reiteration of deformation step 18.

An example of optimization step 21 is depicted in FIGS. 6B-6D. FIG. 6Bdepicts a first iteration of the deformation and the optimization step21 determined that region 40 can be further deformed to reduce supportmaterial. A second iteration is performed and deformation process 21further deforms region 40 as shown in FIG. 6C. After validation, thesystem again determines whether the deformation can be furtheroptimized. In doing so, the system performs another reiteration of thedeformation step. In this illustrative example, deformation process 21produces the deformation shown in FIG. 6D and region 40 is considered tobe optimized according to automated or user determined limits.

After the deformation has been properly validated, a digital template ofthe deformed configuration is communicated to the additive manufacturingdevice for manufacturing step 24. The additive manufacturing device maybe a 3-dimensional printer type device and the information iscommunicated to the additive manufacturing device, using commoncommunication techniques known to a person of ordinary skill in the art,such as wired or wireless communication. Upon receipt of the deformedconfiguration by the additive manufacturing device, support material isadded to the template as needed and the modeled object is printed in adeformed configuration. Once manufactured, the support material isremoved, and the object is ready for use. For a multi-segmented object,each segment is manufactured to produce the complete object.

In an embodiment, the deformed configuration is first presented to theuser at step 22. In an embodiment, the deformed model is presented to auser at step 22 and waits for user instruction on whether to move on tomanufacturing step 24. Moreover, the digital template of the deformedconfiguration may be modified as necessary by a user at step 22. Themodification may be performed in accordance with techniques known to aperson of ordinary skill in the art to place the template into a properformat for a particular additive manufacturing device.

The present invention may be used for both flexible and rigid devicesand assemblies. As explained above, when the object to be manufacturedis flexible, the system simulates an elastic deformation on the model ofthe object to reduce the cross-sectional area of the model. When theobject is rigid, it must be foldable or have mechanical components, e.g.hinges, that allow the object to alter its shape. The deformation stepincludes the steps of identifying the mechanical components and theirdirection of movement and altering the orientation of the object aboutits mechanical components to reduce the cross-sectional area of themodel. The system may rely on user input to determine the mechanicalcomponents and their directions of movement. It should be noted that therigid devices and assemblies introduced herein include objects that arenot completely inelastic, but rather have tighter elastic limits whichresult in minimal/negligible elastic deformation.

An embodiment of the novel method uses a procedural template developedfor Houdini [5, 6]. However, the method is independent to the Houdiniplatform, as it can be demonstrated using a combination of computeraided design and FEA platforms, such as OnShape and FEBio (respectively)[3, 7]. Houdini enables the execution of more complex and fastersimulations and also enables the addition of import and export tools forthe input and output configurations of the 3D model.

Experimentation

A procedural template was created to authenticate the disclosedinvention and present results that highlight its immediate impact on thefield additive manufacturing [5]. A standard cylinder as depicted inFIG. 8 was tested. The model of the object was deformed to reducematerial, time, and costs during additive manufacturing. First, thetemplate was used to demonstrate uniform deformations on an input bodyas depicted in FIGS. 7-9. Gravity, a body force, was used to demonstratethe enforcement of a uniformly-distributed force. The template was alsodesigned to generate measurements of area and volume, which were used toroughly estimate the reduction in build time and support material, whichare depicted in FIG. 7. The simulation results rely heavily on the inputparameters of the FEM embedded within Houdini. Higher resolution modelmeshes or more accurate model material parameters can ensure morerealistic simulation results. The results shown herein areproof-of-concept results.

An optimization protocol was used to adjust the deformation parametersto minimize the amount of printing material, time, and associated costs.The optimization of the deformation parameters included adjusting thebody force values (e.g. modifying the gravity variable by 1G, 2G, 3Getc.). As explained above, the optimization of the deformation scheme isnot restricted to modifying force values, but can also includeoptimizing the type of deformation (e.g. compression, tension, etc.) andthe orientation of the digital model and/or forces to determine whichorientation and deformation will result in the fastest and leastexpensive manufacturing.

The result of the optimization routine may entail single or multiplesolutions. As depicted in FIG. 7, multiple solutions were returned andvalidated until a 5G compression was determined to minimize material,time, and associated costs without exceeding the elastic deformationlimits of the material of the object.

Having finished the procedural template, two sample models of orthoticsleeves, as shown in FIGS. 8-9, were used to measure real estimates oftime and material reduction. FIG. 8 depicts a simple tubular model thatwas designed to take a significant percentage of the Stratasys PolyJetJ750 build volume. FIG. 9 depicts a more complex model based on the 3Dscanning of a human arm and was designed as a real case scenario of anorthotic build. Both models were compressed using the proceduraltemplate and both the undeformed versions 50, 60 and deformed versions52, 62 were sliced using Grab Cad Print (a default slicer for thePolyJet systems) to compare build time and material usage. For thesimple model, the method reduced build time by 40% and the amount ofsupport material by 52%, which translates to approximate $168 worth ofmaterial savings. Two tray estimation tables are provided below for thesimple cylinder model.

Tray Estimations High Quality Pre-Compressed Print Time 2 d 19 h 1 mCylinder Total Materials (g) 5,269 Total Support (g) 4,993 VeroCyan4,757 VeroPureWhite 512 SUP706 4,993

Tray Estimations High Quality Compressed Print Time 1 d 16 h 6 mCylinder Total Materials (g) 4,191 Total Support (g) 2,405 VeroMgnt3,941 VeroPureWhite 250 SUP706 2,405

The method of the present invention reduced the complex model's buildtime by 56% and the amount of require support material by 54%, whichtranslates to over $1,000 in savings in machine time. Two trayestimation tables are provided below for the complex model.

Tray Estimations High Quality MYO_holder_Upper_1.2 Print Time 2 d 21 h58 m Total Materials (g) 497 Total Support (g) 2,336 VeroCyan 263VeroPureWhite 234 SUP706 2,336

Tray Estimations High Quality MYO_holder_Upper_1.2_Collapsed Print Time1 d 6 h 31 m Total Materials 323 (g) Total Support 1,058 (g) VeroCyan216 VeroPureWhite 107 SUP706 1,058

In both cases, a more than 40% reduction in time translated to more than24 hours, while a more than 50% reduction in material equated to morethan ⅓ of the support cartridge's volume. The experimentation clearlyshows that the present invention is a significant improvement toexisting additive manufacturing technology due to its ability todrastically reduce the time, material, and costs associated withadditive manufacturing.

REFERENCES

-   [1] E. B. Tadmor, R. E. Miller and R. S. Elliot, Continuum Mechanics    and Thermodynamics: From Fundamental Concepts to Governing    Equations, Cambridge University Press, 2012.-   [2] J. Bonet and R. D. Wood, Nonlinear Continuum Mechanics for    Finite Element Analysis, Cambridge, N.Y.: Cambridge University    Press, 1997.-   [3] S. A. Maas, G. A. Ateshian and J. A. Weiss, “FEBio: Finite    Elements for Biomechanics,” Journal of Biomechanical Engineering,    vol. 134, 2012.-   [4] M. K. Rausch, G. E. Karniadakis and J. D. Humphrey, “Modeling    Soft Tissue Damage and Failure Using a Combined Particle/Continuum    Approach,” Biomechanics and Modeling in Mechanobiology, vol. 16, no.    1, pp. 249-261, 2017.-   [5] R. Sims, “Compression Simulation Template for Houdini,” Orlando,    2018.-   [6] SideFX, “Houdini,” [Online]. Available: https://www.sidefx.com/.    [Accessed 15 Jul. 2018].-   [7] OnShape, “OnShape,” [Online]. Available:    https://www.onshape.com/. [Accessed 23 Jan. 2017].

All referenced publications are incorporated herein by reference intheir entirety. Furthermore, where a definition or use of a term in areference, which is incorporated by reference herein, is inconsistent orcontrary to the definition of that term provided herein, the definitionof that term provided herein applies and the definition of that term inthe reference does not apply.

The advantages set forth above, and those made apparent from theforegoing description, are efficiently attained. Since certain changesmay be made in the above construction without departing from the scopeof the invention, it is intended that all matters contained in theforegoing description or shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention that, as amatter of language, might be said to fall therebetween.

What is claimed is:
 1. A method for the reducing the time and costsassociated with manufacturing an object through additive manufacturing,comprising: acquiring a digital model of the object to be manufactured,wherein the digital model has a first shape; discretizing the digitalmodel; digitally altering the first shape of the discretized digitalmodel to produce an altered digital model that requires less supportmaterial for additive manufacturing than would be necessary for additivemanufacturing of the discretized digital model; sending the altereddigital model to an additive manufacturing device; manufacturing theobject in accordance with the altered digital model using the additivemanufacturing device; and removing any support material from the objectmanufactured by the additive manufacturing device.
 2. The method ofclaim 1, wherein the step of altering the shape of the discretizeddigital model includes elastically deforming the shape of thediscretized digital model.
 3. The method of claim 1, wherein the step ofaltering the shape of the discretized digital model further includesapplying a simulated force evenly about a body of the discretizeddigital model.
 4. The method of claim 1, wherein the step of alteringthe shape of the discretized digital model further includes reducing across-sectional area of the discretized digital model to reduce theamount of required support material to manufacture the object.
 5. Themethod of claim 1, wherein the digital object to be manufacturedincludes one or more joints and the step of altering the shape of thediscretized digital model further includes manipulating the shape of thediscretized digital model about the one or more joints.
 6. The method ofclaim 1, further including a step of validating that the objectmanufactured can be shaped into the unaltered shape of the digital modelwithout plastically deforming.
 7. The method of claim 6, wherein thestep of validating includes: identifying a manufacturing material;identifying limits for elastic deformation of the manufacturingmaterial; and determining whether the step of altering the shape of thediscretized digital model to produce the altered digital model includesa deformation beyond the limits for elastic deformation of themanufacturing material.
 8. The method of claim 7, further including:responsive to a determination that the altered digital model includes adeformation beyond the limits for elastic deformation of themanufacturing material, altering the shape of the discretized digitalmodel such that the deformation is within the limits for elasticdeformation of the manufacturing material.
 9. The method of claim 1,further including a step of optimizing the shape of the altered digitalmodel to minimize the amount of required support material to manufacturethe object.
 10. The method of claim 1, further including an estimationstep during which the digital model of the object to be manufactured isdivided into at least two segments, whereby each segment can bediscretized and altered in shape to allow for segment-specificalteration-based optimization.
 11. A method for the reducing the timeand costs associated with manufacturing an object through additivemanufacturing, comprising: acquiring a digital model of the object to bemanufactured, wherein the digital model has an unaltered shape; dividingthe digital model of the object into at least two segments; discretizingthe segments to produce discretized segments of the digital model;altering a shape of at least one of the discretized segments to producean altered digital model that requires less support material foradditive manufacturing than would be necessary for additivemanufacturing of the digital model; sending the altered digital model toan additive manufacturing device; manufacturing the object in accordancewith the altered digital model using the additive manufacturing device;and removing any support material from the object manufactured by theadditive manufacturing device.
 12. The method of claim 11, wherein thestep of altering the shape of at least one of the discretized segmentsincludes elastically deforming the shape of the at least one of thediscretized segment.
 13. The method of claim 11, wherein the step ofaltering the shape of at least one of the discretized segments furtherincludes applying a simulated force on at least one of the discretizedsegments.
 14. The method of claim 11, wherein the step of altering theshape of at least one of the discretized segments further includesreducing a cross-sectional area of the at least one discretized segmentto reduce the amount of required support material to manufacture theobject.
 15. The method of claim 11, wherein the digital model to bemanufactured includes one or more joints and the step of altering atleast one of the discretized segments further includes manipulating theshape of the at least one discretized segment about the one or morejoints.
 16. The method of claim 11, further including a step ofvalidating that the object manufactured can be shaped into the unalteredshape of the digital model without plastically deforming.
 17. The methodof claim 16, wherein the step of validating includes: identifying amanufacturing material; identifying limits for elastic deformation ofthe manufacturing material; and determining whether the step of alteringthe shape of the discretized digital model to produce the altereddigital model includes a deformation beyond the limits for elasticdeformation of the manufacturing material.
 18. The method of claim 17,further including: responsive to a determination that the altereddigital model includes a deformation beyond the limits for elasticdeformation of the manufacturing material, altering the shape of atleast one of the discretized segments such that the deformation iswithin the limits for elastic deformation of the manufacturing material.19. The method of claim 11, further including a step of optimizing theshape of the altered digital model to minimize the amount of requiredsupport material to manufacture the object.
 20. A method for thereducing the time and costs associated with manufacturing an objectthrough additive manufacturing, comprising: acquiring a digital model ofthe object to be manufactured, wherein the digital model has anundeformed shape; dividing the digital model of the object into at leasttwo segments; discretizing the segments to produce discretized segmentsof the digital model; deforming a shape of at least one of thediscretized segments to produce a deformed digital model that requiresless support material for additive manufacturing than would be necessaryfor additive manufacturing of the digital model; validating that theobject to be manufactured can be shaped into the undeformed shape of thedigital model without plastically deforming; sending the deformeddigital model to an additive manufacturing device; manufacturing theobject in accordance with the deformed digital model using the additivemanufacturing device; and removing any support material from the objectmanufactured by the additive manufacturing device.